2007 ISUZU KB P190 lock

MANUAL TRANSMISSION 7B1-91
9.Disassemble the 1st inside ring, 1st outside ring, and
1st block ring.
10.Remove the needle bearing.
11.Use a pair of snap ring pliers to remove the clutch hub snap ring.


226RS031
12.Use a bench press and the bearing remover 5-8840-
0015-0 to remove the 2nd gear together with 1st-2nd
synchronizer assembly, 2nd block ring, 2nd outside
ring, and inside ring.
Disassemble the synchronizer assembly.
226RW 220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
13. Remove the needle bearing from the mainshaft.
14. Remove the bearing snap ring.
15. Remove the front roller bearing by performing the following steps.
• Remove the ring, outer race and bearing
assembly by using a bench press and remove
r
5-8840-0015-0.
• Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RW 219
16. Remove the center roller bearing from the counter
gear shaft.




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ISUZU KB P190 2007

7B1-92 MANUAL TRANSMISSION
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Block Ring and Dog Teeth Clearance
• Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.


226RS035
If the measured value exceeds the specified limit,
the block ring must be replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.031 in)



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-93
1st-2nd Synchronizer (3-CONE)
• Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.


226RS036
If the measured value exceeds the specified limit,
the 1st-2nd synchronizer assembly must be
replaced.
Block Ring and Dog Teeth Clearance
Standard Limit
1.5 mm (0.059 in) 0.8 mm (0.031 in)
Block Ring and Insert Clearance
• Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.


226RS037
If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.


Block and Insert Clearance
Standard Limit
3rd-4th 3.46 - 3.76 mm
(0.136 - 0.148 in) 4.0 mm
(0.157 in)
1st-2nd 3.86 – 4.16 mm
(0.152 - 0.164 in) 4.9 mm
(0.193 in)
Rev.5th 3.59 - 3.91 mm
(0.141 - 0.154 in) 4.1 mm
(0.161 in)

Clutch Hub and Insert Clearance
• Use a thickness gauge to measure the clearance
between the clutch hub and the insert.


226RS038
If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.
Clutch Hub and Insert Clearance
Standard Limit
1st-2nd3rd-4th 0.01 – 0.21 mm
(0.0004 - 0.0083 in) 0.3 mm
(0.012 in)
Rev-5th 0.09 – 0.31 mm
(0.0035 - 0.0122 in) 0.4 mm
(0.016 in)



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ISUZU KB P190 2007

7B1-94 MANUAL TRANSMISSION
Mainshaft Run-out
• Install the mainshaft to V-blocks.
• Use a dial indicator to measure the mainshaft
central portion run-out.


226RS039
If the measured mainshaft run-out exceeds the
specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Gear Inside Diameter
• Use an inside dial indicator to measure the gear
inside diameter.


226RS040
If the measured value is less than the specified limit,
the gear must be replaced.


Gear Inside Diameter
Standard Limit
1st
3rd 45.000 - 45.013 mm
(1.771 - 1.772 in) 45.100 mm
(1.776 in)
2nd 52.000 - 52.013 mm
(2.047 - 2.048 in) 52.100 mm
(2.051 in)
Rev. 48.000 - 48.013 mm
(1.889 - 1.890 in) 48.100 mm
(1.894 in)
5th 32.000 - 32.013 mm
(1.259 - 1.260 in) 32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft
Clearance
• Use a micrometer to measure the idler gear shaft
diameter.
• Use an inside dial indicator to measure the idle
r
gear inside diameter.

226RS041
• Calculate the idler gear and idler gear shaft
clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
If the measured value exceeds the specified limit,
the idle gear and/or the idler gear shaft must be
replaced
Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)


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ISUZU KB P190 2007

7B1-96 MANUAL TRANSMISSION
• Use the bearing installer 5-8840-2194-0 to install
the ring.




RTW 57BSH000101
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
3. Install the bearing snap ring to the counter gear
shaft.
4.
Apply engine oil to the needle bearing and the 2nd
gear thrust surfaces.
Install the needle bearing and the 2nd gear to the
mainshaft.
The 2nd gear dog teeth must be facing the
transmission rear side.


226RS046

5.
Assemble the 2nd inside ring, 2nd outside ring, and
the 2nd block ring.
•
Apply engine oil to the synchronizer ring friction
surfaces.


226RS047
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing



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ISUZU KB P190 2007

7B1-98 MANUAL TRANSMISSION

226RS031
9. Install the needle bearing, 1st block ring, 1st outside
ring, 1st inside ring, and 1st gear.
•
Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
• The 1st gear dog teeth must be facing the
transmission front side.


226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring

10. Install the 1st gear thrust bearing and the race to the
main shaft.
The thrust bearing side must be facing the
transmission front side.


226RS054
11. Apply engine oil to the mainshaft ball bearing and the mainshaft.
Install the ball bearing and needle bearing collar to
the mainshaft.
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.


226RS055



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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-99
12. Apply engine oil to the needle bearing and the 3rd
gear thrust surfaces.
Install the needle bearing and the 3rd gear to the
mainshaft.
The 3rd gear dog teeth must be facing the
transmission front side.


226RS056
13. Install the 3rd block ring.
14. Check and install the 3rd-4th synchronizer assembl
y
by using the following steps:
1. Check that the inserts (3) fit snugly into the clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft.
The clutch hub face with the heavy boss must be facing the 3rd gear side.


226RS049

226RW 221
15. Select and install mainshaft snap ring using the
following instructions:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.


226RS058
There are three snap ring sizes available.
The snap rings are color-coded to indicate thei
r
thickness, as shown in the figure.


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ISUZU KB P190 2007

7B1-100 MANUAL TRANSMISSION

226RS021
Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 in)
Snap Ring Availability
Thickness Color Coding
1.80 mm (0.071 in) W hite
1.85 mm (0.073 in) Yellow
1.90 mm (0.075 in) Blue
• Use a pair of snap ring pliers to install the snap
ring to the mainshaft.
The snap ring must be fully inserted into the
mainshaft snap ring groove.
16. Install the top block ring.
Apply grease to the needle bearing inner and oute
r
circumferences and install the needle bearing in the
top gear shaft.
17. Use a bench press to install the top gear shaft ball bearing to the top gear shaft.


226RS059
The snap ring groove of the ball bearing must be
facing the transmission front side.
18. Use a pair of snap ring pliers to install the top gea
r
shaft snap ring to the top gear shaft.


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ISUZU KB P190 2007